System and Method for Molding Intraocular Lenses

Abstract

Systems and methods for molding an intraocular lens (IOL) are disclosed. The system for making an intraocular lens comprises a mold insert and a spacer adapted to be positioned between the first and second portions of the mold insert. The method of making a dual-element intraocular lens comprises providing a mold insert including a spacer.

1 . A system for molding a dual-element intraocular lens having a first optical element and a second optical element comprising:
 a mold insert comprising a first portion constructed and arranged to define an inwardly facing portion of a first optic cavity, and comprising a second portion constructed and arranged to define an inwardly facing portion of a second optic cavity, the first and second portions being movable relative to one another; and   a spacer adapted to be positioned between the first and second portions of the mold insert.   
     
     
         2 . The system of  claim 1 , further comprising a first cavity block constructed and arranged to define an outwardly facing portion of the first optic cavity and a second cavity block constructed and arranged to define an outwardly facing portion of the second optic cavity. 
     
     
         3 . The system of  claim 2 , wherein the first and second portions of the mold insert are hinged. 
     
     
         4 . The system of  claim 2 , wherein the spacer is constructed and arranged to allow the first and second portions of the mold insert to collapse. 
     
     
         5 . The system of  claim 4 , wherein the first and second cavity blocks are constructed and arranged to define an outwardly facing surface of a haptic of the intraocular lens. 
     
     
         6 . The system of  claim 5 , wherein the mold insert is constructed and arranged to define an inwardly facing surface of the haptic of the intraocular lens. 
     
     
         7 . The system of  claim 6 , wherein the spacer is positioned between the first and second portions of the mold insert. 
     
     
         8 . The system of  claim 7 , wherein the spacer is constructed and arranged so that removal of the spacer enables collapsing of the mold insert to reduce the restriction created between the mold insert and the haptic. 
     
     
         9 . The system of  claim 6 , wherein the spacer is constructed and arranged so that removal of the spacer enables collapsing of the mold insert to reduce the restriction created between the mold insert and at least one of the first optical element and the second optical element of the intraocular lens. 
     
     
         10 . The system of  claim 8 , wherein the spacer is further constructed and arranged to collapse the mold insert when removed to reduce the restriction created between the mold insert and at least one of the first optical element and the second optical element of the intraocular lens. 
     
     
         11 . A system for making a dual-element intraocular lens comprising:
 a mold insert configured to form at least one portion of an intraocular lens and to release the at least one portion of the formed intraocular lens.   
     
     
         12 . The system of  claim 11 , wherein the mold insert is configured to form an inwardly facing portion of the intraocular lens. 
     
     
         13 . The system of  claim 12 , further comprising a cavity block configured to form an outwardly facing portion of the intraocular lens. 
     
     
         14 . The system of  claim 13 , further comprising a spacer constructed and arranged to separate portions of the mold insert. 
     
     
         15 . A method of molding a dual-element intraocular lens comprising:
 providing a mold insert within a cavity to define an inwardly facing portion of a first optic cavity and an inwardly facing portion of a second optic cavity;   injecting a lens forming material into the first optic cavity and the second optic cavity to form a first optical element and a second optical element; and   collapsing the mold insert to permit movement of at least one of the inwardly facing portion of the first optic cavity and the inwardly facing portion of the second optic cavity.   
     
     
         16 . The method of  claim 15 , wherein the inwardly facing portion of the first optic cavity and the inwardly facing portion of the second optic cavity are optical grade surfaces. 
     
     
         17 . The method of  claim 15 , wherein the step of collapsing the mold insert comprises removing a spacer. 
     
     
         18 . The method of  claim 15 , further comprising providing a first cavity block to define an outwardly facing portion of the first optic cavity, and providing a second cavity block to define an outwardly facing portion of the second optic cavity. 
     
     
         19 . The method of  claim 18 , further comprising removing the mold insert from at least one of the first cavity block and the second cavity block. 
     
     
         20 . The method of  claim 19 , wherein the step of providing a mold insert further comprises providing the mold insert to define an inwardly facing portion of a haptic cavity. 
     
     
         21 . The method of  claim 20 , wherein the steps of providing the first cavity block and the second cavity block comprises providing the first cavity block and the second cavity block to define an outwardly facing portion of the haptic cavity.